Avoid Battery Failure

l New batteries should be given a full charge before use.

Avoid charging in environments above room

temperature.

l New batteries need to be charged and discharged

(cycled) several times before reaching full capacity

(20 - 50 cycles, depending on battery type). Usage

should be limited during this period.

l Battery cables should be intact, and the connectors

kept tight at all times. Systematic inspection is

recommended.

l Vent caps should be kept in place and tight during

vehicle operation and battery charging. Deep cycle

batteries need to be equalised periodically. Equalising

is an extended, low current charge performed after the

normal charge cycle. This extra charge helps keep all

cells in balance.

l Actively used batteries should be equalised once per

week. Manually timed charges should have the charge

time extended approximately 3 hours. Automatically

controlled chargers should be unplugged and

reconnected after completing a charge.

For best battery life, batteries should not be discharged below 80% of their rated capacity. Measure the discharge in percentage by purchasing a single dual battery monitor.

l Battery chargers should be matched to fully charge

batteries in an eight-hour period. Defective chargers

will damage batteries or severely reduce their

performance. In situations where multiple batteries

are connected in series, parallel or series/parallel,

replacement battery(s) should be of the same size, age

and usage level as the companion batteries. Do not put

a new battery in a pack, which has 50 or more cycles.

l As batteries age, their maintenance requirements

change. This means longer charging time and/or higher

finish rate (higher amperage at the end of the charge).

Periodic battery testing is an important preventative maintenance procedure.

l Lead acid batteries should be brought up to full

charge at the earliest opportunity. Avoid continuously

operating batteries in a partially charged condition.

This will shorten their life and reduce their capacity.

l Always make sure that the charger and battery system

match. An undersized charger will never get the job

done, no matter how long you let it run. An oversized

charger will cause excess gassing and heat; this

situation could cause explosions or other damage.

l Voltage checks (open circuit, charged and discharged)

can locate a bad battery or weak battery. Load Testing

will pick out a bad battery when other methods fail.

A weak battery will cause premature failure of

companion batteries.

l Extreme temperatures can substantially affect battery

performance and charging. Cold reduces battery

capacity and retards charging. Heat increases water

usage and can result in overcharging. Very high

temperatures can cause “thermal run-away” which

may lead to an explosion or fire. If extreme temperature

is an unavoidable part of an application, consult your

local Battery World expert about ways to deal with

the problem.

Inactivity can be extremely harmful to all lead acid

batteries. If seasonal use is anticipated, we recommend

the following:

a. Completely charge the battery before storing.

b. Remove all electrical connections from the

battery, including series/parallel connectors.

c. Store the battery in as cool a place as possible.

However, do not store in a location which will

consistently be below 0°C. Batteries will

discharge when stored, the lower the

temperature the lower the self-discharge.

d. When not in use, boost every two months.

Copyright: the intellectual property contained within this document is the property of Battery World Australia Pty Ltd and can only be copied with the express permission of the author. Prices are correct at time of writing but may be subject to variation.Battery World can not be held responsible for any loss or failures caused by installation or any other reason.

Proper care and maintenance of Deep Cycle Batteries

More than 80 Battery World Stores around Australia. Phone 13 17 60 to connect to your nearest store or visit our website www.batteryworld.com.au

Undercharging

Low charge voltage or insufficient recovery, ie stop/start,

very short run motoring or only using the vehicle once a

week may cause a gradual discharge of the battery;

which leads to sulphation and the ultimate destruction

of the battery.

Alternators should be checked for correct charge rate on

a regular basis.

Battery Corrosion

High temperatures can cause “mushy” plates, rapidly

increasing plate corrosion.

High antimony content in the lead alloy helps to reduce

corrosion, unlike softer calcium alloy lead plates. In the

end, the battery becomes an electro chemical reaction

bathed in an acid solution. A battery has a normal

operating life of about 3- 3½ years after which the

chemical reaction will deteriorate until the battery will

no longer start the vehicle.

Open Circuit failure

Sometimes the battery just ceases. It started the car in

the morning but at lunchtime would not even bring up

dash lights.

This is usually open circuit or no voltage output. Broken/

corroded cell to cell connection or broken/corroded busbar.

Both of these will break the circuit so that there

is no voltage output from the battery.

Short Circuit failure

Vibration can cause plates to distort and touch each other.

Should a positive plate make direct contact with a negative

plate a short will occur and the battery fails. High quality

batteries have envelope separators which encase one

value plate to prevent contact with another.

Shorts can also be caused by impure water top up, such as

water with heavy iron deposits. Zinc and other metals

present in water can also cause plate failure. Always use

demineralised or distilled water, to top up your battery.

Right battery for the application

There are many batteries on the Australian market

ranging from cheap to very expensive. How long the

battery lasts depends very much on the usage, almost no

two applications are the same. Even with the same model

vehicle, one may have high power accessories, one may

use air conditioning.

We can make generalisations but there is no substitute for

experience. Tailoring a battery is like fitting the right pair

of shoes. The battery has to perform to meet the needs of

the usage. Fitting a light-weight battery into a heavy duty

vehicle with high power demands is only a short term

solution and in the long run, more expensive than buying

the correct battery first.

Prevention is the best cure

If possible, keep batteries fully charged either with regular

daily use, ensuring that your alternator and charging

systems are fully functional and set to appropriate

charging Voltage. If this is not possible we recommend the

use of a standby charger. Depending on the size of the

battery standby chargers are available from 0.75 Amp

upwards. These products are designed to top up charge

after use and then switch to a floating mode with enough

power to keep the battery at optimum charge.

In some cases the charger may be permanently installed in

the vehicle.

There are many chargers at a variety of price levels.

If the battery is in a remote location a solar module can

be used. Depending on the size of battery or battery

bank, solar panels are suitable to assist in keeping a

battery at peak charge.

You’re not expected to know everything

about batteries, that’s our job! Visit us today

for your free battery and system check.

Electrolyte starvation (low water level)

Australia’s harsh climate creates enormous demands

on auto batteries. High ambient temperature and

extreme under bonnet temperature causes high rates

of water evaporation. If the busbar in the top of the

battery is not fully covered sulphation can occur and

accelerate corrosion.

Water loss also causes an increased concentration of acid

within the body of the battery and also causes acceleration

of plate corrosion.

Failure to maintain the battery’s water level does void

any warranty so it’s well worth checking the battery at

every service or, if living in tropical climates, possibly

every week. Some batteries have a magic eye or visual

hydrometer which monitors one cell as an indicator if the

battery needs service.

Vibration

Serious vibration will cause battery damage by shaking

out the lead paste that makes a battery plate. Batteries

should be properly held down and, in the case of some

trucks, an under battery rubber mat should be installed

to prolong the life.

Overcharging

If the vehicles charge system is not properly regulated

the battery may receive excessive voltage or continuous

charge. Not being shut down when the battery is fully

charged will result in faster water loss, and plate growth.

Visual indicators that a battery is being overcharged are:

l Spatter of electrolyte across the top of the battery

(excited electrolyte caused by high charge rate).

l Heavy black sooty deposits under the vent caps.

l Bulging of the battery (plate growth pushes the

ends outward).

Infrequently used vehicles

When questioned about batteries that fail, the common

answer is the vehicle was not used for some time.

Typical are the hobby car, motorcycle or jet ski, boat etc.

Not all are big boy’s toys. Rural Fire Brigades have trucks

on standby but if the battery fails, lives could be lost.

Sulphation is the enemy of batteries

When a battery is allowed to discharge below the nominal

12.5 Volts a process called sulphation starts to damage

your battery. Effectively the chemicals from the electrolyte

start to separate; the sulphur from the battery acid

commences to form lead sulphate crystals on the battery

plate. Within 3 months the battery will be seriously

damaged with a build up of crystals causing the plate to

harden and resist charge, or fail to hold charge.

Eventually, the lead sulphate cystals will short out

the cell rendering the battery totally useless.

Recovery

Once sulphation has attacked the battery there will

always be some permanent damage but there are some

chargers on the market that use multi stage charging

that can recover a partially sulphated battery. These are

chargers with a ripple or pulse charge stage. In the initial

stages of charge the charger uses a pulse or ripple

charge to dislodge lead sulphate from the plates this will

then recombine with the sulfuric acid electrolyte. Talk to

the Battery World Franchisee or staff about a charger to

suit your battery needs.

Other reasons for battery failure

A flat or discharged battery is not necessarily a failure!

Continual charge and discharge of a normal automotive

battery is highly detrimental to the life of the battery.

However, some batteries are specifically designed with

thicker plates to withstand heavy cycling. This will lead

to premature failure. Every time you leave the lights on

and flatten the battery, you take about

6 months off the life of the battery, and recharging that

battery from flat can rarely be done in the vehicle.